Removable Battery Component Carrier for Modular EV Systems
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Solution Overview
Problem
Conventional battery modules require the entire system to be detached for replacing or repairing a defective submodule, which is cumbersome, especially for large, expensive, and heavy modules, making maintenance and storage difficult.
Innovation Solution
A modular battery system with removable battery component carriers that allow separate attachment and detachment of submodules, featuring a cooling channel for heat management and electrical connections for monitoring and control, enabling individual component replacement and integration of submodules into a unified cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire battery module is detached for replacing a defective submodule, then the battery system can be repaired, but the maintenance process becomes cumbersome and time-consuming
Solution Approach 1:
The battery module is divided into independent submodules that can be separately removed and replaced. Each submodule is a discrete unit containing specific battery cells, allowing defective submodules to be individually identified and replaced without affecting other submodules, thereby enabling quick maintenance without detaching the entire battery module.
Solution Approach 2:
The battery module structure is designed to be dynamically reconfigurable, allowing submodules to be easily added, removed, or replaced during operation. This dynamic design enables flexible maintenance where defective submodules can be quickly swapped out and the system can be reconfigured to continue operation with remaining functional submodules.
2Ease of repair
If the entire battery module is detached for repair, then defective components can be replaced, but the process becomes expensive and complex
Solution Approach 1:
The battery module is segmented into standardized submodules with uniform interfaces and connection mechanisms. This segmentation allows repair technicians to work with individual submodules rather than the entire complex assembly, simplifying the repair process and reducing the skill level and equipment required for maintenance.
Solution Approach 2:
Defective submodules can be extracted from the battery module without removing other functional submodules. This extraction capability allows for targeted repair of only the problematic components, reducing repair complexity and cost by avoiding unnecessary handling and potential damage to functional parts of the system.
3Ease of repair
If the entire battery module is detached for maintenance, then repairs can be performed, but storage and handling become difficult
Solution Approach 1:
The heavy battery module is divided into lighter submodule units that can be individually handled and stored. This segmentation reduces the weight and size of each maintenance unit, making them easier to transport, store in workshops, and manipulate during repair operations without requiring heavy equipment or specialized storage facilities.
4Reliability
If all components are connected together for mechanical integration, then the battery system functions properly, but individual component replacement becomes impossible
Solution Approach 1:
The battery system is organized into modular submodules that maintain functional integration while enabling individual replacement. Each submodule contains complete functional units with integrated cells, connectors, and management circuits, allowing the system to maintain reliability through proper submodule connections while enabling easy exchange of individual submodules.
Solution Approach 2:
The submodules are designed with universal interfaces and standardized connection mechanisms that allow any submodule to replace any other submodule in the system. This universality ensures that the battery system maintains full functionality regardless of which specific submodules are installed, enabling flexible replacement and repair operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates easy assembly, disassembly, and replacement of battery submodules, reducing costs and improving maintenance efficiency by allowing individual component separation and integration within the battery system, while maintaining safety and functionality.
Implementation Method 1
a cooling channel capable of discharging heat generated from a battery submodule
Implementation Method 2
configured to be connected to a cooling channel of an adjacent removable battery component carrier and a cooling channel of a carrier frame to make up an integrated cooling channel throughout an entire cooling system
Data Source
AI summary
A removable battery component for receiving a battery submodule and being mechanically and electrically connectable to other removable battery component carriers and/or a carrier frame is provided. The removable battery component carrier includes a bottom plate, a pair of side walls perpendicular to the bottom plate and extending along two facing corners of the bottom plate, a pair of end plates perpendicular to the bottom plate and the side wall, extending along two facing corners of the bottom plate, and mechanically connected to the side walls and/or the bottom plate to fix the plurality of battery cells together. A cell cover extends parallel to the bottom plate to form a receiving space of the battery submodule along with the bottom plate, the side wall, and the end plate.